Breast pad and method of manufacture



July 28, 1959 E. L. FITZGERALD BREAST PAD AND METHOD OF MANUFACTUREFiled Oct. 12 1955 ATI'QENEY,

2,896,623 BREAST PAD AND METHOD OF MANUFACTURE Edward L. Fitzgerald,Green Bay, Wis., assignor to Diana Manufacturing Company, Green Bay,Wis., a corporation of Wisconsin 7 I This invention relates to a breastpad and method of manufacture.

Pulp or tissue wadding is laminated in a layer of uniform thicknessbetween external plies of tissue. The resulting web is advanced througha pair of dies one of which forms successive portions of the web to theshape of the desired pad, while, at the same time, uniting the plieswith the pulp by pressure deformation to effect fibrous interlock. Asubsequent die, which may be mounted on the same carrier punches out theformed pad. The successive pads thus blanked from the web are receivedon a conveyor. Either before or after the die operation, the plies aredesirably stitched along lines which will be on minor chords for furtherassuring the permanent connection of the parts.

Aside from the fibrous interlock of the plies at spaced points about theperiphery of the pad, a feature of the product is the offset centralportion which receives the nipple of the patients breast but is ofuniform thickness without such compression as would change itsabsorptive capacity relative to the rest of the pad. The stitching isalso a feature, this having been found desirable to resist sterilizingtreatment which might free some of the plies if the fiber interlock weresolely relied upon to maintain connection between plies.

In the drawings:

Fig. 1 is a plan view of a pad embodying the invention.

Fig. 2 is a view taken in cross section on the line 2-2 of Fig. 1.

Fig. 3 is a diagrammatic view illustrating a portion of themanufacturing process, the dies used being shown partially in sideelevation and partially in section.

The pad shown at 5 comprises inner and outer tissue plies 6 and 7 withan intervening layer of filling material at 8 which is of substantiallyuniform density and thickness throughout except in the areas 9 spacedaround the perimeter of the pad where fibrous interlock has occurred.The tendrils indicated at 10 in Fig. 2 diagrammatically illustratefibers displaced by the punches used in the mating dies which shape thepad. These fibers of the tissue become interengaged with fibers of thefilling material layer 8 in such a way as to tend to maintain theseveral plies in connection.

In the preferred manufacture of the pad, a web 11 which comprises thetissue and filler plies as above described is fed through a die setwhich includes a lower platen 12 and an upper platen 13. The lowerplaten has a convex portion 14 complementary to theconcave interior 15shown in the finished pad of Fig. 2. The portion 16 of the platen iscomplementary to the outwardly deformed nipple-receiving pocket 17 ofthe pad.

The female die 18 has complementary surfaces 19 corresponding to theoutwardly convex annular portion 20 of the finished pad. It also has arecess at 21 complementary to the offset and outwardly convex centralarea 22 at the outside of the n pp e-receiving pocket.

The complementary surfaces of the upper and lower dies are uniformlyspaced at all points within the annu- I I 2 lar rim portion 23 of thepad which is approximately planiform except at the points where thefiber lockis effected. p

-To effect fiber lock, the lower platen 12 is provided with pegs at 25for which the die 18 is provided with sockets at 26.- The interaction ofthe pegs with the web as the pegspush the web into the sockets 26 produces the outwardly convex bosses 9 and interlocks the fibers 10 asabove described.

The platen 13 carries a blanking punch 30 cooperating with a blankingdie 31 formed in platen 12 from which an opening 32 extends downwardlythrough the platen. In each reciprocation of the platen 13 respectingthe platen 12, a new area of the web is formed as above described and apreviously formed area is punched from the web and discharged throughthe port 32 onto the delivery conveyor 34.

In order that movement of web 11 may be continuous, the entire die setmay be reciprocated unitarily along ways 35. The die set is actuated bycam 36, cam follower 37, lever 38 and link 39 to move at the speed ofthe web during punch operation and retraction.

The lines of stitching shown at 45 are desirably (although notnecessarily) applied to the web before the web is passed through thedies. This is done on an ordinary sewing machine or a pair of sewingmachines. The lines of stitching extend transversely of the finishedpad. They may be close to the outer perimeter of the convex area 20 inwhich case much of the stitching is confined to the flat rim 23. Thiszone about the perimeter of the pad is annular in the circular padshown.

For many purposes, the stitching is unnecessary, since the fiberinterlock achieved in the protuberances 9 fastens the plies quitesecurely. However, if the pads are sterilized in a hospital autoclave,the resulting softening of the fibers may tend to release the interlock.Hence, when the pads are expected to be thus sterilized, the stitchingis desirably used and the specific location shown has been foundpeculiarly satisfactory in that it accomplishes the purpose without anyimpairment of the softness of the pad portions which are under pressureengagement with the breast of the wearer.

If the lines of stitching are parallel this facilitates the use ofautomatic sewing equipment and permits two or more sewing machine headsto function concurrently. It will be observed that the lines ofstitching are not required to transverse any of the protuberances 9despite their proximity to the fiat rim at 23.

The fact that the filler is not compressed at 46 across thenipple-receiving pocket 17 is a substantial advantage both inmaintaining full absorptiveness of the filler and in minimizing pressureon the nipple. Compression at this point would result in objectionablehardness and a decrease in absorptive capacity. The method ofmanufacture as herein disclosed leaves all plies in uniform thicknessand density and at uniform spacing except in the areas of fiberinterlock and protuberances 9, these being confined to the outer rim.

I claim:

1. A breast pad comprising an outwardly convex multi-ply disk havingadjacent its center a further outwardly convex portion providing anipple-receiving pocket, the outwardly convex and pocket-formingportions of said disk being of substantially uniform thickness anddensity and comprising material of substantially like absorptivecapacity, the disk being provided with an outer rim having at intervalsembossed protuberances in which fibers of the several plies areinterlocked.

2. A breast pad comprising inner and outer plies of tissue and anintervening filler ply, the several plies having concentric outwardlyconvex annular portions and central outwardly displaced pocket-formingportions,

References Cited in the filer of this patent UNITED STATES PATENTSWandel July 29, Bronson Apr. 18, Schnaittacher July 14, Fourness Jan.25, Pitcher May 2, St'einberger Feb. 20, De Iorio Oct. 7, Hardy June 9,Snowdon Dec. 15, Aagesen v Mar. 3,

FOREIGN PATENTS Great Britain Aug. 14,

